For the inside, I tried to use microfleece and the pee seemed to just run on out. LOL Maybe I didn't buy the right stuff. I have made TONS of different types of diapers, and this is what I have figured out; do snaps instead of Aplix/velcro. DEF don't do WM velcro. The snaps are well worth it. I would rather pin my contours/all in ones than to ever use Aplix/velcro again. But, that is JMO. I have made covers, I have done AIOs, I have done plain diapers, made my own prefolds, etc. These are my tips:
1. need two layers, inner and outer. That can be outer double sided fleece, and inner cotton/hemp/whatever is absorbant. If you have thin absorbant fabric, do 2 full layers on diaper side. Or the absorbant fabric on both sides if you are doing a few covers instead of AIOs. Don't skimp on fabric, the better the fabric, the longer they last, and they will get washed a lot. They can make it through more than one child too, if I didn't like making them so much. LOL
2. Make an inner pad and outer pad. Inner pad is sewn in the middle of the layers. Outer pads are for when they wet more and is just placed in the middle of the diaper and comes out for washing. No snap is needed. Make extras for nighttime.
3. Casings for elastic and sewing at each end is better than sewing it down the middle of the elastic, and the casings go in the middle of the layers too.
4. Prefolds and pins work just as well as fitted, contours, etc. Especially in a pinch. Or prefolds in the covers.
5. Place elastic casings inside legs just a little more to make a ruffle, because leakage is less likely, and it looks TOOO cute.
6. You can reuse, and recycle fabrics for diapers. I buy nice fabric for the inside and outside layers of the diapers and pads. And, use old towels, receiving blankets, cotton blankets of any type, old flannel sheets in the middle unseen layers. It is sooo cheap that way, and keeps stuff out of the landfill. Thrift shops are good for this if you don't have this stuff on hand or can't replace; and wash on VERY HOT.
7. And, again, snaps instead of Aplix/velcro. It is more costly by a little bit, but you will thank me. I tried the velcro saver idea too. Uh, too busy for that.
8. I preferred wooly fleece or double sided fleece for the AIO cover, or for covers, over PUL. PUL AIOs take forever to dry. Fleece breathes better.
9. Gussets in the contour or fitted diapers or the plain covers work WONDERS!! They are put in just like in the disposies that have them. It has a little extra fabric, and keeps all the poo in. I LOVE them!! Just a little extra work, but worth it.
10. "Quilting" through the layers in the pads/diapers can make them just a little more absorbant and less bulky. If you use cotton knit, it also makes them more stable.
Well, that is what I can think of. Kymberli